Lochinvar SYNC User manual

HIGH EFFICIENCY COMMERCIAL BOILERS
www.Lochinvar.com
DESIGNER’S GUIDE SYNC COMMERCIAL BOILER
Up to 98%
Thermal Efficiency

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Designer’s Guide / SYNC Boiler
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Table of Contents
Combustion & Ventilation Air …………………… Page 2
Venting ….…………………………………………….. Page 5
Gas ….….…………….……………….………………… Page 13
Water …..……………………..……………………….. Page 15
Electricity & Controls ……………………………….. Page 21
Other Details ..……………………………………….. Page 26
Appendix A ….……..…………………………………. Page 29
Appendix B …………………………………………… Page 34
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Designer’s Guide / SYNC Boiler
At Lochinvar, we know that designing a boiler is hard work. Designing a boiler system is
no picnic either. Demands for greater efficiency and elaborate system control have
made systems more complex.
This designers guide will break down the system requirements that match the SYNC
boiler to assure safe operation, highly efficient heating and long life.
There are five major elements of boiler system design:
Combustion &
Ventilation Air
(See page 2)
Venting
(See page 5)
Gas
(See page 13)
Water
(See page 15)
Electricity &
Controls
(See page 21)
Plus many other important details:
Locations Suggested Piping Diagrams
(See page 27 for “Location of Unit”) (See Appendix “A”)
High Altitude Requirements Component List
(See page 28 for “High Altitude Applications”) (See Appendix “B”)
Gas
Water
Electricity&
Controls
Combustion
&
Ventilation
Air
Venting

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Designer’s Guide / SYNC Boiler
Chapter 1 – Combustion and
Ventilation Air
The first, important design consideration is air. Everybody’s gotta breathe. Even boilers need air.
Air seems easy enough. You stand in the equipment room and you breathe comfortably, don’t
you? Open a door. Open a window. This is a big room. There’s lots of air in here for the boiler,
right?
The average person inhales 400 to 500 cubic feet of air in a 24 hour period. A one million Btu/hr
boiler will draw 226.38 cubic feet of air every MINUTE! A 20 by 20 by 8 foot equipment room
holds 3200 cubic feet of air. That’s a volume of air to last you or me over six days. A one million
Btu/hr SYNC will consume 3200 cubic feet of air in 14 minutes.
Therefore, a good, easy flow of clean air is 100% necessary for clean, efficient combustion. So,
we need to provide a permanent and uninterrupted flow of air to the boiler. The SYNC boiler is
designed to receive combustion air by one of TWO methods. The boiler may draw combustion
air from the room or have the air ducted directly to the boiler from an exterior space.
This chapter explains the methods for “air from the room”. Chapter 2 explains “air ducted directly
to the boiler”. Again, this chapter lists several techniques to size the air openings that will deliver
room air. If there are other appliances in the room requiring air, their air requirements must be
including when sizing the air openings.
Provisions for combustion and ventilation air must be
designed and installed in accordance with “Air for
Combustion and Ventilation”, of the latest edition of the
National Fuel Gas Code, ANSI Z223.1, (in Canada, the
latest edition of CGA Standard B149 Installation Code for
Gas Burning Appliances and Equipment) or applicable
provisions of the local building codes.
NEGATIVE PRESSURE IN THE EQUIPMENT ROOM
It is important to NEVER have a negative pressure on the equipment room. Exhaust fans are
popular in equipment rooms to exchange the air. If the exhaust fan pulls air OUT, then a negative
pressure occurs in the room. The combustion and ventilation air must be sized to supply all the
equipment PLUS the air for the exhaust fan.
COMBUSTION AND VENTILATION AIR SIZING CALCULATIONS
The sizing calculations in this section are based on “Free Area”. The
louvers or grill used on the air openings must have a net free area equal
to or greater than the value derived in the calculations. The Free Area in
a louver or grill is defined as the open, unblocked area. The louvers,
grills, mesh, blades, all will block a given amount of space in the louver’s
overall dimension. Consult the louver manufacturer for exact net free
area of the louver.
A
ir

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Designer’s Guide / SYNC Boiler
1. COMBUSTION AIR FROM OUTSIDE
If air is taken directly from outside the building with no
duct, provide two permanent openings to the
equipment room:
(a) Combustion air opening, with a minimum free area
of one square inch per 4000 Btu/hr input (5.5 cm²
per
kW). This opening must be located within 12" (30 cm)
of the bottom of the enclosure.
(b) Ventilation air opening, with a minimum free area of
one square inch per 4000 Btu/hr input (5.5 cm²
per
kW). This opening must be located within 12" (30 cm)
of the top of the enclosure.
2. COMBUSTION AIR THROUGH DUCTS
If combustion and ventilation air is taken from the outdoors using
a duct to deliver the air to the equipment room, each of the two
openings should be sized based on a minimum free area of one
square inch per 2000 Btu/hr (11 cm²
per kW) of input.
3. COMBUSTION AIR FROM INTERIOR
SPACE
If air is taken from another interior space,
each of the two openings specified above
should have a net free area of one square
inch for each 1000 Btu/hr (22 cm²
per kW) of
input, but not less than 100 square inches
(645 cm²).
THE SYNC COMES WITH LOUVER CONTACTS AS STANDARD EQUIPMENT. THE CONTACTS WILL
OPEN AND CLOSE A MOTORIZED LOUVER ON EACH CALL FOR HEAT.
Did you Know?

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Designer’s Guide / SYNC Boiler
4. DIRECT OUTSIDE AIR, SINGLE OPENING
If a single combustion air opening is provided to bring
combustion air in directly from the outdoors, the opening
must be sized based on a minimum free area of one
square inch per 3000 Btu/hr (7 cm²
per kW). This opening
must be located within 12" (30 cm) of the top of the
enclosure.
The combustion air must be free of any contaminants or chemical fumes. Salts, refrigerants and
solvents introduced into the combustion process will result in the formation of corrosive acids that
will damage the appliance and the vent.

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Designer’s Guide / SYNC Boiler
Chapter 2 – Venting
Venting is another important design element for the installation of a gas fired appliance. It has a
variety of choices, many different vent configurations to chose from, rules and regulations that
govern the installation and most important of all, it bears a requirement for human safety.
Lochinvar offers five different vent configurations on the SYNC boiler to meet the building’s
requirements. They are…
Vertical Vent with Air from the Equipment Room
Vertical Vent with Air from the Rooftop
Vertical Vent with Air from the Sidewall
Sidewall Vent with Air from the Equipment Room
Sidewall Vent with Air from the Sidewall
Part 1
Vent Categories
Lochinvar offers five venting options with the SYNC that must be installed with approved
Category IV vent material. Below is the vent category diagram, standard throughout the industry.
The four basic Vent Categories are determined by two characterisitics, Condensation and
Pressure.
In all vent configurations, the SYNC boiler will operate in Category IV. The modulation of the
burner down to 10% of the boiler’s input will put low temperature flue products in the stack that
will condense. The boiler’s blowers are designed to push the flue products through the exhaust
system with a consistent positive pressure.
Always use Category IV approved non-corrosive vent material and always seal the joints and
connections 100% gas tight in order to prevent condensation and flue gas leakage.
CATEGORY I
Non‐Condensing
Non‐PositivePressure
CATEGORY III
Non‐Condensing
PositivePressure
CATEGORY II
Condensing
Non‐PositivePressure
CATEGORY IV
Condensing
PositivePressure
SPILLAGE OF FLUE PRODUCTS AND CARBON MONOXIDE EMISSIONS PRODUCED BY THE
COMBUSTION PROCESS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH.
Warning
Venting

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Designer’s Guide / SYNC Boiler
VERTICAL VENT WITH COMBUSTION AIR FROM EQUIPMENT ROOM.
The flue outlet terminates on the rooftop. The combustion air is drawn
from the equipment room.
BULLET POINTS
Category IV vent material is required, such as AL29-4C or PVC/CPVC.
All vent joints and seams must be sealed gastight and may not be common vented.
All vent material for this configuration including vent termination will be obtained locally.
The air is delivered to the equipment room by means defined in Chapter 1 of this
designer’s guide.
When venting with PVC, the first ten feet of pipe must be CPVC for heat protection. See
page 12 of the installation manual for details.
 VENTVENTVENT
MODELDIAMETERMIN.LENGTHMAX.LENGTH
SBN10006"12ft100ft
SBN13006"12ft100ft
SBN15006"12ft100ft
A 90° VENT ELBOW IS EQUAL TO 5 LINIER FEET OF VENT PIPE AND ALL VENT ELBOWS MUST BE
ACCOUNTED FOR IN THE TOTAL VENT LENGTH. SEE SYNC I & O MANUAL FOR DETAILS.
Did you Know?

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Designer’s Guide / SYNC Boiler
SIDEWALL VENT WITH COMBUSTION AIR FROM EQUIPMENT ROOM.
The flue outlet terminates out the sidewall. The combustion air is drawn
from the equipment room.
BULLET POINTS
Category IV vent material is required, such as AL29-4C or PVC/CPVC.
All vent joints and seams must be sealed gastight and may not be common vented.
All vent material for this configuration including vent termination will be obtained locally.
The sidewall termination plate may be used with PVC or CPVC vent material.
The air is delivered to the equipment room by means defined in Chapter 1 of this
designer’s guide.
When venting with PVC, the first ten feet of pipe must be CPVC for heat protection. See
page 12 of the installation manual for details.
 VENTVENTVENT
MODELDIAMETERMIN.LENGTHMAX.LENGTH
SBN10006"12ft100ft
SBN13006"12ft100ft
SBN15006"12ft100ft

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Designer’s Guide / SYNC Boiler
VERTICAL VENT WITH COMBUSTION AIR FROM THE ROOFTOP.
The flue outlet terminates on the rooftop. The combustion air is ducted to
the appliance from outdoors through the rooftop. This is true Direct Vent
with the flue termination and the air inlet port in the same pressure zone.
BULLET POINTS
Category IV vent material is required, such as AL29-4C or PVC/CPVC.
All vent joints and seams must be sealed gastight and may not be common vented.
All other vent material for this configuration including vent termination will be obtained
locally.
The air is delivered to the appliance via a separate duct. The air intake material can be
galvanized pipe, PVC, CPVC or ABS and must be sealed gas tight.
When venting with PVC, the first ten feet of pipe must be CPVC for heat protection. See
page 12 of the installation manual for details.
 AIRINTAKEAIRINTAKEAIRINTAKEVENTVENTVENT
MODELDIAMETERMIN.LENGTHMAX.LENGTHDIAMETERMIN.LENGTHMAX.LENGTH
SBN10006"12ft100ft6"12ft100ft
SBN13006"12ft50ft6"12ft50ft
SBN13007"12ft100ft7"12ft100ft
SBN15006"12ft50ft6"12ft50ft
SBN15007"12ft100ft7"12ft100ft